Mercury 2.8 Diesel Operation & Maintenance Manual
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Mercury 2.8 Diesel Operation & Maintenance Manual

Sterndrive models
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2.8 and 4.2 Diesel
Sterndrive Models
O P ERAT I O N &
M AI N T EN AN CE
MAN U AL

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Summary of Contents for Mercury 2.8 Diesel

  • Page 1 2.8 and 4.2 Diesel Sterndrive Models O P ERAT I O N & M AI N T EN AN CE MAN U AL...

  • Page 3: Read This Manual Thoroughly

    The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.
  • Page 4 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Manual included with the product. The Warranty Manual contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section 1 - Getting to Know Your Power Package Identification................2 Remote Controls..............8 Serial Number Decal............2 Panel Mount Features............ 9 Engine Data Label.............. 2 Console Mount Features..........9 Bravo Sterndrive Serial Number and Identification..... 3 Power Trim...............
  • Page 6 Power‑Assisted Steering and Power Trim Fluids.... 35 Approved Power Trim Fluids........35 Approved Power‑Assisted Steering Fluids....35 Approved Paints..............35 Section 4 - Maintenance Owner and Operator Responsibilities........38 Flushing the Seawater System—Sterndrive Models..64 Dealer Responsibilities............38 With the Boat out of the Water........64 Maintenance................
  • Page 7 Incorrect Engine Temperature........105 Operate)................106 Low Engine Oil Pressure..........105 Section 7 - Customer Assistance Information Owner Service Assistance............. 108 Contact Information for Mercury Marine Customer Service Local Repair Service............108 ..................109 Service Away From Home..........108 Customer Service Literature..........109 Stolen Power Package.............
  • Page 8 Page iv 90-8M0113987 DECEMBER 2015...
  • Page 9 Section 1 - Getting to Know Your Power Package Section 1 - Getting to Know Your Power Package Table of Contents Identification................2 Remote Controls.............. 8 Serial Number Decal............2 Panel Mount Features ..........9 Engine Data Label............2 Console Mount Features ......... 9 Bravo Sterndrive Serial Number and Identification..

  • Page 10: Section 1 - Getting To Know Your Power Package

    Section 1 - Getting to Know Your Power Package Identification The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.

  • Page 11: Bravo Sterndrive Serial Number And Identification

    Section 1 - Getting to Know Your Power Package Bravo Sterndrive Serial Number and Identification The Bravo sterndrive serial number, gear ratio, model number, and bar code are embedded in the ground plate on the port side of the sterndrive. 33533 Bravo sterndrive information on ground plate The serial number is also stamped on the driveshaft housing behind the back cover.

  • Page 12: Features And Controls

    Section 1 - Getting to Know Your Power Package The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser dealers. 44425 Serial number location on gimbal housing Features And Controls Audio Warning System Your power package is equipped with an audio warning system.

  • Page 13: Lanyard Stop Switch

    Section 1 - Getting to Know Your Power Package • "OFF" In the "OFF" position, all electrical circuits are off. The engine will not operate with the key switch in the "OFF" position. • "ACC" In the "ACC" position, any accessory connections to the electrical circuits can be operated. The engine will not operate with the key switch in the "ACC"...

  • Page 14: Keep The Lanyard Stop Switch And Lanyard Cord In Good Operating Condition

    Section 1 - Getting to Know Your Power Package • Low‑sided sport boats • Bass boats • High‑performance boats Accidental ejections can also occur from: • Poor operating practices • Sitting on the seat or gunwale at planing speeds • Standing at planing speeds •...

  • Page 15: Smartcraft Speedometer, Tachometer, And Digital Gauges

    Section 1 - Getting to Know Your Power Package VesselView 4 and 7 are equipped with a micro SD card port that allows an authorized OEM or dealership to import the personality configuration. It can also be use by the owner to import pictures or graphics. When more than one VesselView is used, either as a triple or quad‑engine application for multiple helms, the same mico SD card can be used to download those configurations.

  • Page 16: Emergency Stop Switch

    Mercury Diesel repair facility. Remote Controls Your boat may be equipped with Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control.

  • Page 17: Panel Mount Features

    Section 1 - Getting to Know Your Power Package Panel Mount Features Neutral lock button Throttle‑only button Lanyard stop switch Control handle tension adjustment screw Control handle Trim and tilt button mc77019-1 Neutral lock button. Prevents accidental shift and throttle engagement. The neutral lock button must be pushed into move the control handle out of neutral.

  • Page 18: Power Trim

    Section 1 - Getting to Know Your Power Package Control handles. The shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear and continue pushing forward to increase speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed.

  • Page 19: Single-Engine Trim And Trailer

    Reset the circuit breaker. If the breaker remains open, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your Mercury Diesel authorized repair facility. 90-8M0113987...

  • Page 20: Overload Protection-Port Side Power Distribution Box

    If the breaker remains open, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your Mercury Diesel authorized repair facility. Circuit breakers provide protection for the engine electrical system as indicated. The circuit breaker panel is located within a power distribution box mounted on the engine control module.

  • Page 21: Vessel Integration Panel (Vip) Overload Protection

    After finding and correcting the cause of the overload, connect the starting battery and turn the ignition switch to the run position. The circuit breaker should automatically reset. If a circuit breaker fails to reset, contact your Mercury Diesel authorized...

  • Page 22: Engine Guardian System

    SeaCore Equipped Drives SeaCore Components and Castings Mercury MerCruiser SeaCore power packages are equipped with additional stainless steel components and particular aluminum castings with special coatings. Do not replace SeaCore components with non‑SeaCore. Use only the specified Mercury MerCruiser SeaCore components and castings on these power packages.
  • Page 23 Section 1 - Getting to Know Your Power Package Stainless steel fasteners are subject to galling when installed without lubrication. Galling can result in fastener destruction, improper clamp loads, or both. Galled fasteners may appear to torque properly, but still have incorrect clamp loads. Apply lubricant 2‑4‑C with PTFE or an equivalent, on the threads of stainless steel fasteners during installation to avoid galling.
  • Page 24 Section 1 - Getting to Know Your Power Package Notes: Page 16 90-8M0113987 DECEMBER 2015...
  • Page 25 Section 2 - On the Water Section 2 - On the Water Table of Contents Safe Boating Recommendations.......... 18 While Boat Is Stationary ........24 Carbon Monoxide Exposure..........19 High‑Speed and High‑Performance....... 25 Be Alert To Carbon Monoxide Poisoning ..... 19 Passenger Safety In Pontoon Boats and Deck Boats...

  • Page 26: Safe Boating Recommendations

    Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.

  • Page 27: Carbon Monoxide Exposure

    Section 2 - On the Water Be alert. • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed.

  • Page 28: Poor Ventilation

    The power package must be equipped with a gear ratio and propeller that allows the engine to operate at wide open throttle (WOT) at the engine's rated speed (RPM). Use of Mercury Diesel engines in applications that do not meet specified operational parameters is not approved.

  • Page 29: Operation Chart

    At temperatures of –20° C (–4° F) and below, use a coolant heater to improve cold starting. • If operating in arctic temperatures of –29° C (–20° F) or lower, consult your Mercury Diesel authorized repair facility for information about special cold weather equipment and precautions.

  • Page 30: Drain Plug And Bilge Pump

    Check all items listed in Section 5—Maintenance Schedules and the Operation Chart. • Perform any other necessary procedures as indicated by your dealer or Mercury Diesel authorized repair facility. Important Information – SmartStart IMPORTANT: This power package is equipped with SmartStart. SmartStart performs all appropriate starting operations upon initial start switch actuation.

  • Page 31: Engine Warm-Up

    Check for coolant leaks. Check the coolant hoses and connection pipes of the heat exchanger, fluid coolers, aftercooler, water pump, and drain fittings. Locate and correct any problems, or see your Mercury Diesel authorized repair facility if you are unable to determine the problem.

  • Page 32: Shifting

    Section 2 - On the Water Shifting NOTICE Shifting into gear at engine speeds above idle will damage the drive system. Shift the drive into gear only when the engine is operating at idle. NOTICE Failure to rotate the propeller shaft when shifting gears or forcing the shift mechanism while the engine is not operating can result in product damage.

  • Page 33: High-Speed And High-Performance

    If your boat is considered a high‑speed or high‑performance boat, we recommend that you never operate it at its high‑speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat. For additional information, refer to the Hi‑Performance Boat Operation booklet from your Mercury Diesel authorized repair facility.

  • Page 34: Impact With Underwater Hazards

    After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury Diesel repair facility for a thorough inspection and any necessary repair.

  • Page 35: Conditions Affecting Operation

    Section 2 - On the Water Conditions Affecting Operation Weight Distribution (Passengers and Gear) Inside the Boat Shifting weight to rear (stern): • Generally increases speed and engine RPM • Causes bow to bounce in choppy water • Increases danger of following wave splashing into the boat when coming off plane •...

  • Page 36: Propeller Selection

    It is important to follow this procedure to properly break in the engine. IMPORTANT: Mercury Marine recommends that the boat not be accelerated hard until this procedure has been completed. IMPORTANT: Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor. If the engine does not start, wait one minute to allow the starter motor to cool;...

  • Page 37: After The 20-Hour Break-In Period

    Check the engine oil level frequently. Add oil as needed. High oil consumption is normal during the break‑in period. After the 20-Hour Break-In Period To help extend the life of your power package, Mercury Marine recommends the following: • Change the engine oil and filter and the transmission fluid at the interval indicated in the Maintenance Schedule. Refer to Specifications and Maintenance.
  • Page 38 Section 2 - On the Water Notes: Page 30 90-8M0113987 DECEMBER 2015...

  • Page 39: Section 3 - Specifications

    Section 3 - Specifications Section 3 - Specifications Table of Contents Fuel Requirements............... 32 2.8 ................. 34 Diesel Fuel in Cold Weather..........32 4.2 ................. 34 Antifreeze/Coolant..............32 Bravo Sterndrive Fluid Specifications—Diesel....34 Engine Oil................33 Power‑Assisted Steering and Power Trim Fluids..35 Engine Specifications............

  • Page 40: Fuel Requirements

    Mercury diesels are required to use grade 2–D ULSD (ultra‑low sulphur diesel) fuel meeting ASTM Standards D975 (or fuel rated Diesel DIN EN 590), and having a minimum cetane rating of 51.

  • Page 41: Engine Oil

    Shell Myrina Mopar Texaco Ursa Super TD Engine crankcase Obtain Locally Wintershall Multi‑Rekord Veedol Turbostar Wintershall VIiva 1 These oils are approved by Mercury Marine and Marine Power Europe. For all temperature operation use 15W‑40 oil. 90-8M0113987 DECEMBER 2015 Page 33...

  • Page 42: Engine Specifications

    Part Number Engine oil (with filter) 8.9 (9.4) 15W40 4‑cycle Diesel Engine Oil 92‑858042K01 Closed cooling system 11 (11.6) Mercury Extended Life Antifreeze 92‑877770K1 All models Capacity liters (US qt) Fluid Type Part Number Engine oil (with filter) 13.8 (14.6) 15W40 4‑cycle Diesel Engine Oil...

  • Page 43: Power-Assisted Steering And Power Trim Fluids

    Part Number Power Trim and Steering Fluid 92‑858074K01 SAE Engine Oil 10W‑30 Obtain locally SAE Engine Oil 10W‑40 Approved Paints Description Part Number Mercury Diesel White 8M0108939 Mercury Light Gray Primer 92‑80287852 Mercury Phantom Black 92‑802878Q1 90-8M0113987 DECEMBER 2015 Page 35...
  • Page 44 Section 3 - Specifications Notes: Page 36 90-8M0113987 DECEMBER 2015...
  • Page 45 Section 4 - Maintenance Section 4 - Maintenance Table of Contents Owner and Operator Responsibilities........38 Flushing the Seawater System—Sterndrive Models..64 Dealer Responsibilities............38 With the Boat out of the Water ......64 Maintenance................. 38 With the Boat in the Water ........66 Do‑It‑Yourself Maintenance Suggestions......

  • Page 46: Owner And Operator Responsibilities

    It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation, and to return the unit to a Mercury Diesel authorized repair facility for a periodic checkup.

  • Page 47: Maintenance Schedules

    Maintenance Schedules Routine Maintenance IMPORTANT: Some procedures can be done by the owner or operator, while others should be performed by a Mercury Diesel authorized repair facility. Before attempting maintenance or repair procedures not covered in this manual we recommended that you purchase the appropriate Mercury Service Manual, and read it thoroughly.

  • Page 48: Scheduled Maintenance

    Section 4 - Maintenance Task Interval Maintenance to Be Performed • Check the battery connections and fluid level. • Lubricate the propeller shaft and tighten the propeller nut to the specified torque. If operating in only freshwater, this maintenance may be extended to every four months. •...

  • Page 49: Engine Oil

    Section 4 - Maintenance Engine Oil NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

  • Page 50: Changing Oil And Filter

    Section 4 - Maintenance Capacity Fluid Type Engine oil (with filter) 8.9 L (9.4 U.S. qt) 4‑Cycle 15W40 Marine Engine Oil Capacity Fluid Type Engine oil (with filter) 13.8 L (14.6 U.S. qt) 4‑Cycle 15W40 Marine Engine Oil IMPORTANT: Always use the dipstick to determine the amount of oil required to refill the engine oil. Install the oil fill cap.

  • Page 51: Sterndrive Gear Lube

    Section 4 - Maintenance 11. Disconnect and discard the old filter element. Discard the old O‑ring from the top piece. Typical Top piece O‑ring Filter element 16603 12. Install the new O‑ring. Apply lubricant to the O‑ring. Tube Ref No. Description Where Used Part No.

  • Page 52: Checking

    IMPORTANT: If more than 59 ml (2 fl. oz.) of High Performance Gear Lube is required to fill the gear lube monitor, a seal may be leaking. Damage to the sterndrive may occur due to lack of lubrication. Contact your Mercury Diesel authorized repair facility.

  • Page 53: Changing

    Section 4 - Maintenance Changing Remove the gear lube monitor from the bracket. Gear lube monitor bracket Gear lube monitor and cap Retaining strap 5500 Empty the contents of the gear lube monitor into a suitable container. Install the gear lube monitor in the bracket. Remove the propeller.
  • Page 54 IMPORTANT: If any water drains from the fill and drain plug hole, or if the gear lube appears milky, the sterndrive is leaking and should be checked immediately by your Mercury Diesel authorized repair facility. Lower the sterndrive so that the propeller shaft is level.

  • Page 55: Power Trim Fluid

    Section 4 - Maintenance 14. Remove the pump from the sterndrive fill and drain plug hole. 15. Quickly install the sealing washer and the fill and drain plug. Torque to the following specifications. mc79506-1 14621 All Bravo Models Shown Fill and drain plug Sealing washer 19777 Description...

  • Page 56: Filling

    Section 4 - Maintenance Observe the fluid level. The fluid level must be between the "MIN" and "MAX" lines on the reservoir. 7876 Reservoir "MIN" and "MAX" lines Fill as necessary with the specified fluid. See Filling. Tube Ref No. Description Where Used Part No.

  • Page 57: Changing

    92-858074K01 Install the fill cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your Mercury Diesel authorized repair facility. Power‑Assisted Steering Fluid IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission fluid (ATF) in the power‑assisted steering system.

  • Page 58: Filling

    Section 4 - Maintenance IMPORTANT: If fluid is not visible in the fluid reservoir, see your Mercury Diesel authorized repair facility. Filling Remove the fill cap and dipstick and observe the fluid level. Add the specified fluid to bring the fluid level up to the proper level.

  • Page 59: Changing

    Bottom of fill neck 23248 Description Where Used Part Number Mercury Extended Life Antifreeze Closed‑cooling system 92‑877770K1 IMPORTANT: When installing the pressure cap, be sure to tighten it securely to prevent coolant loss. Install the pressure cap. Tighten securely. Changing Change (replace) the engine coolant at the prescribed interval.

  • Page 60: Inspection

    Section 4 - Maintenance Remove the air filter cartridge from the air filter bracket mounted on the turbocharger inlet. Shown removed from the engine for clarity only Air filter cartridge Air filter bracket 12618 Inspection The air filter cannot be cleaned. Replace the air filter if it is dirty or contaminated. Replace the air filter if the foam element is deteriorated or torn.

  • Page 61: 4.2 Air Filter

    Section 4 - Maintenance 4.2 Air Filter Removal Loosen the clamp and remove the oil separator vent hose. Loosen the clamp and remove the air filter housing from the turbocharger inlet. Oil separator vent hose Air filter housing Turbocharger Clamp 25881 Remove the air filter element from the air filter housing Air filter housing...

  • Page 62: Installation

    Section 4 - Maintenance Installation Slide the filter element into the air filter housing. Ensure that the element is seated fully into the air filter housing. Air filter housing Air filter element 25893 NOTE: The warning labels on the air filter housing must be visible after the air filter housing is installed. Install the air filter housing on to the turbocharger inlet.

  • Page 63: Draining

    Section 4 - Maintenance The engine‑mounted water‑separating fuel filter is equipped with a water‑in‑fuel (WIF) sensor that should alert the operator when water is present in the filter. This fuel filter needs to be replaced at specified intervals or whenever water is detected in the fuel, whichever comes first.
  • Page 64 Section 4 - Maintenance Remove the water‑separating fuel filter and sealing ring from the mounting bracket. Do not use a filter wrench. Typical Water‑separating fuel filter 23459 NOTE: It may be necessary to keep the existing drain cap and use it on the new filter. Be sure to replace the O‑ring on the drain cap.

  • Page 65: Filling

    13. Connect the battery cables. 14. Start and operate the engine. Check the filter connection for fuel leaks. If leaks exist, recheck filter installation. If leaks continue, stop the engine immediately and contact your Mercury Diesel authorized repair facility. Filling A type of hand pump and primer plunger is located on the fuel filter bracket and is used to •...

  • Page 66: Fuel System

    Section 4 - Maintenance Loosen the air vent (bleed) screw on the fuel filter bracket. Typical Air vent screw 23469 Move the primer plunger up and down repeatedly. The filter is full when an air‑free stream of fuel flows from the air vent screw.

  • Page 67: Fuel Tank Cleaning And Flushing

    Section 4 - Maintenance Fuel Tank Cleaning and Flushing IMPORTANT: Diesel fuel should not be left in the tank during winter storage, as an accumulation of rust, sludge, and wax residue will form. Refer to the boat manufacturer's instructions and clean the fuel tank at specified intervals. Unless specified otherwise, flush and clean the diesel fuel tank every 1000 hours or five years, whichever occurs first.
  • Page 68 Section 4 - Maintenance Remove the drain plug, or fitting (if equipped), from the aft end cover of the engine oil cooler. Typical engine Engine oil cooler Drain plug, or fitting if equipped 23295 NOTE: In the following steps, the hoses may require lowering or bending to allow seawater to drain completely. Disconnect the seawater inlet hose from the connector on the seawater pump hose and drain.

  • Page 69: Sterndrive Water Inlets Check

    Section 4 - Maintenance Install the sealing washer and drain plug, if equipped. 37290 Typical After the seawater has completely drained, apply sealant to the threads of the drain plugs or fittings (if equipped). Install and tighten the drain plugs or fittings. Tube Ref No.

  • Page 70: Checking The Seawater Pickups

    Section 4 - Maintenance Checking the Seawater Pickups Ensure that the water inlet holes for the seawater pickup are clean and not obstructed. 16776 Typical through-hull seawater pickup Typical through-transom seawater pickup Water inlet holes Cleaning the Seawater Strainer, if Equipped NOTICE An open seawater strainer or seacock during some service or maintenance procedures can introduce water into the boat, causing damage or sinking the boat.
  • Page 71 Section 4 - Maintenance Clean any debris from the strainer housing. Flush both the strainer and housing with clean water. Inspect the cover gasket and replace if damaged. Strainer cove Strainer basket Seal 37287 CAUTION Seawater leaking from the seawater strainer could cause excess water in the bilge, damaging the engine or causing the boat to sink.

  • Page 72: Flushing The Seawater System-Sterndrive Models

    Section 4 - Maintenance Screw the strainer cover on. Strainer cove Strainer basket Seal 37287 Open the seacock, if equipped, or remove the plug and reconnect the seawater inlet hose. Upon first starting the engine, check for leaks or air in the system that would indicate an external leak. Flushing the Seawater System—Sterndrive Models Flushing the seawater system with fresh water is needed only for applications operating in saltwater, brackish water, polluted water, or water with a high mineral content to avoid salt or silt buildup.
  • Page 73 Section 4 - Maintenance Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine. 9192 Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1 Blocks off the front water inlet holes on the dual water inlet gearcases. 9194 Connect a flushing hose from a water tap to the flushing attachment.

  • Page 74: With The Boat In The Water

    Section 4 - Maintenance Place the remote control in neutral, idle speed position and start the engine. NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply. Operate the engine at idle speed in neutral for about ten minutes or until the discharge water is clear.

  • Page 75: Engine Seawater Pump Inspection

    Engine Seawater Pump Inspection IMPORTANT: Mercury strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. Remove and inspect the engine seawater pump at the interval specified in the Maintenance Schedule. See your Mercury Diesel authorized repair facility.

  • Page 76: Filling The Closed-Cooling System

    After the coolant has drained completely, install the intake and exhaust manifold drain plug, the heat exchanger drain plug, and the engine block drain plug. Tighten all drain plugs securely. If required, clean the closed‑cooling system. See your local Mercury Diesel authorized repair facility. Fill the system with the specified coolant. Refer to Filling the Closed Cooling System.

  • Page 77: Corrosion Protection

    To help control the effects of galvanic corrosion, Mercury power packages come with several sacrificial anodes and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection refer to the Marine Corrosion Protection Guide.

  • Page 78: Cleaning And Inspection

    Section 4 - Maintenance Remove the anode assembly (anode plug and the sacrificial anode) from the top of the aftercooler end cover. Aftercooler end cover Anode assembly 23266 On 4.2 models, remove the anode assembly (anode plug and the sacrificial anode) from the aft end of the fluid cooler. Anode assembly Fluid cooler 23710...

  • Page 79: Installation

    Section 4 - Maintenance Sacrificial anode measurements (new) Length 19 mm ( 3/4 in.) Diameter 16 mm ( 5/8 in.) Discard the sealing washer. Installation Install a new sealing washer on the anode assembly (anode plug with the sacrificial anode). Anode assembly Sealing washer 19227...

  • Page 80: Sterndrive Corrosion Protection Components

    Section 4 - Maintenance NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. Ensure that the seawater pickup pump is supplied cooling water. Start the engine and check for leaks Sterndrive Corrosion Protection Components To help control the effects of galvanic corrosion, sterndrives come with several sacrificial anodes and other corrosion protection...
  • Page 81 MerCathode System—The electrode assembly, if equipped, replaces the anode block. The system should be tested to ensure adequate output. Perform the test when the boat is moored, using a Quicksilver reference electrode and test meter. Contact your Mercury Diesel authorized repair facility. 90-8M0113987...
  • Page 82 Section 4 - Maintenance Description Location Figure Alpha sterndrive Mounted on the underside of the lower gearcase. gearcase anodic plate 22405 Alpha sterndrive Mounted on the underside of the gimbal housing. gimbal housing anode 53380 Bravo sterndrive Mounted on the underside of the lower gearcase. gearcase anode plate 20336 Alpha and Bravo sterndrive...

  • Page 83: Continuity Circuit-Bravo Sterndrive

    Section 4 - Maintenance Paint the power package. Annually spray the power package components on the inside of the boat with Corrosion Guard to protect the finish from dulling and corrosion. You may also spray external power package components. Keep all lubrication points, especially the steering system, shift, and throttle linkages, well lubricated. Flush the cooling system periodically, preferably after each use.
  • Page 84 Section 4 - Maintenance Inspect the driveshaft housing‑to‑gear housing ground plate inside the anode cavity for a loose or faulty connection. Sterndrive anodic plate cavity Ground plate (inside anode cavity) 27285 Inspect the gimbal housing ground wires for loose connections, broken connectors, or frayed wiring. Gimbal housing‑to‑gimbal ring ground wire Gimbal housing‑to‑trim cylinder ground wires 7006...

  • Page 85: Mercathode

    Section 4 - Maintenance Inspect the sterndrive ground plate for loose or broken connections. Sterndrive‑to‑bell housing ground plate 27264 Inspect the continuity washers under the hydraulic manifold block fasteners for a loose or faulty connection. Continuity washers 9957 Inspect the sterndrive U‑joint bellows ground clips and exhaust tube ground clip for loose or faulty connections. Exhaust tube ground clip shown, U-joint bellows ground clips similar Exhaust tube ground clip 19627...

  • Page 86: Boat Bottom Care

    If using copper‑based or tin‑based anti‑fouling paints, observe the following: • Avoid any electrical interconnection between the paint and the Mercury MerCruiser product, anodic blocks, or MerCathode system by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on the transom of the boat around these items.

  • Page 87: Sterndrive Surface Care

    Maintain a complete paint covering on the sterndrive. • Check the finish regularly. Prime and paint nicks and scratches using Mercury enamel paint and touch up paint. Use only tin‑based antifouling paint or its equivalent on or near aluminum surfaces below the waterline.
  • Page 88 Section 4 - Maintenance If the steering cable has grease fittings, turn the steering wheel until the steering cable is fully retracted into the cable housing. Apply approximately three pumps of grease from a typical hand‑operated grease gun. Steering cable grease fitting 6221 Tube Ref No.

  • Page 89: Throttle Cable

    Section 4 - Maintenance Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Tie bar pivot points 8M0078630 SAE25W‑40 Upon first starting the engine, turn the steering wheel several times to starboard and then port to ensure that the steering system operates properly before getting underway.

  • Page 90: Transom Assembly

    Section 4 - Maintenance Transom Assembly Lubricate the gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun. Gimbal bearing grease insert 19979 Tube Ref No. Description Where Used Part No. Extreme Grease Gimbal bearing grease insert 8M0071842 Engine Coupler IMPORTANT: These engines are equipped with a sealed engine coupler.

  • Page 91: Sterndrive, Bellows, And Engine Alignment

    8M0071842 fittings Sterndrive, Bellows, and Engine Alignment IMPORTANT: Have your Mercury Diesel authorized repair facility perform the maintenance procedures listed, or refer to the appropriate Mercury MerCruiser Bravo Sterndrive Service Manual. Lubricate the U‑joint shaft splines and the O‑rings. U‑joint shaft splines U‑joint shaft O‑rings...

  • Page 92: Maintaining Torques

    Section 4 - Maintenance Rotate the bell housing in the upward and side‑to‑side directions to inspect the exhaust tube, shift cable bellows, and clamps. U‑joint bellow Exhaust tube Bell housing Gimbal ring Gimbal housing Shift cable bellows 22189 Check the engine alignment. 7936 Alignment tool End of alignment tool to insert through gimbal housing assembly...

  • Page 93: Engine Mounts

    Section 4 - Maintenance Tighten the gimbal ring U‑bolt nuts to the specified torque. Transom assembly Gimbal ring U‑bolt nuts 19624 Description lb‑in. lb‑ft Gimbal ring U‑bolt nuts for 7/16 in. U‑bolt – Engine Mounts Loosen the rear engine mount bolts 1 to 1‑1/2 turns. Retorque the rear engine mount bolts. Rear engine mount Transom plate mount Rear engine mount bolt...

  • Page 94: Bravo One Models

    Section 4 - Maintenance Bravo One Models Straighten the bent tabs of the tab washer on the propeller shaft. Propeller Tab washer Drive sleeve adapter Tab bent down Propeller nut 4750 Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate. Wood block Propeller Propeller nut under socket...

  • Page 95: Bravo Three Models

    Section 4 - Maintenance Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate. Wood block Propeller Propeller nut under socket Turn the propeller shaft nut counterclockwise to remove the nut. Slide the propeller and attaching hardware from the propeller shaft. Bravo Two Propeller shaft splines Forward thrust hub...

  • Page 96: Bravo Sterndrive Propeller Installation

    Section 4 - Maintenance Slide the propeller and the thrust hub off the propeller shaft. Bravo Three Aft propeller nut Aft propeller Aft propeller thrust hub Front propeller nut Front propeller Front propeller thrust hub Propeller shaft anode screw Flat washer Star washer Propeller shaft anode 5304...

  • Page 97: Bravo Three

    Section 4 - Maintenance NOTE: The propeller torque stated is a minimum torque value. Description lb‑in. lb‑ft – Bravo One propeller nut Then align tabs with grooves Models equipped with the tab washer: Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer.

  • Page 98: Drive Belts

    Section 4 - Maintenance Install the propeller shaft anode and secure with the screw. Tighten the screw to the specified torque. Bravo Three Rear propeller nut Rear propeller Rear propeller thrust hub Front propeller nut Front propeller Front propeller thrust hub Propeller shaft anode screw Flat washer Star washer...

  • Page 99: Replacement

    Section 4 - Maintenance • Glazed surfaces 21062 Check the operation of the automatic tensioner and associated components. Position a suitable tool in the automatic tensioner release slot. Rotate the automatic tensioner in the direction of the arrow. Automatic tensioner Release slot 23256 Release the automatic tensioner and allow it to glide back slowly.

  • Page 100: Power-Assisted Steering Pump Belt

    Section 4 - Maintenance Power‑Assisted Steering Pump Belt Inspection Inspect the belt for proper tension and for the following: • Excessive wear • Cracks • Fraying • Glazed surfaces Replace the belt if worn or damaged. See Replacement. Check belt tension by depressing the upper strand of the belt, with moderate hand pressure, at the point shown. The belt must correspond to the specifications in the following table.

  • Page 101: Replacement

    Section 4 - Maintenance Power‑assisted steering drive belt tension Belt deflection, with moderate hand pressure 5 mm (3/16 in.) Torque the power‑assisted steering pump mounting and tensioning flange bolts. 2.8 shown, 4.2 similar Mounting bolts 23767 Description lb. in. lb. ft. Power‑assisted steering pump mounting bolts Replacement Remove the serpentine belt.

  • Page 102: Battery

    Section 4 - Maintenance Use the adjustment screw to move the power‑assisted steering pump to tension the power‑assisted steering belt. Mounting bolts Adjustment screw 23650 Power‑assisted steering drive belt tension Belt deflection, with moderate hand pressure 5 mm (3/16 in.) Torque the power‑assisted steering pump mounting and tensioning bolts.
  • Page 103 Section 4 - Maintenance In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM will reset itself. The engine will now run normally. This ECM shut down usually happens so fast that the engine just appears to have an ignition miss.
  • Page 104 Section 4 - Maintenance Notes: Page 96 90-8M0113987 DECEMBER 2015...

  • Page 105: Section 5 - Storage

    Section 5 - Storage Section 5 - Storage Table of Contents Cold Weather (Freezing Temperature), Seasonal Storage, Seasonal Storage Instructions........99 and Extended Storage............98 Extended Storage Instructions........100 Cold Weather (Freezing Temperature) Storage.... 98 Battery................. 100 Preparing Your Power Package for Seasonal or Recommissioning...............

  • Page 106: Cold Weather (Freezing Temperature), Seasonal Storage, And Extended Storage

    Section 5 - Storage Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage IMPORTANT: Mercury recommends this service be performed by a Mercury Diesel authorized repair facility. Damage caused by freezing is not covered by the Mercury Limited Warranty. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage.

  • Page 107: Seasonal Storage Instructions

    If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged. IMPORTANT: Mercury recommends the use of propylene glycol antifreeze in the seawater section of the cooling system for cold weather (freezing temperature), seasonal storage, or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.

  • Page 108: Extended Storage Instructions

    Read all precautions and perform all procedures found in Seasonal Storage Instructions. IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to direct sunlight. Remove the seawater pump impeller and store away from direct sunlight. Refer to a Mercury Diesel authorized repair facility for additional information and service.
  • Page 109 Section 5 - Storage 12. Carefully inspect the engine for fuel, oil, fluid, water, and exhaust leaks. 13. Check the steering system, shift, and throttle control for proper operation. 90-8M0113987 DECEMBER 2015 Page 101...
  • Page 110 Section 5 - Storage Notes: Page 102 90-8M0113987 DECEMBER 2015...
  • Page 111 Section 6 - Troubleshooting Section 6 - Troubleshooting Table of Contents Diagnosing Electronically Controlled Fuel System Problems Battery Will Not Charge..........105 .................... 104 Remote Control Operates Hard, Binds, Has Excessive Troubleshooting Charts............104 Free‑play, or Makes Unusual Sounds......105 Starter Motor Will Not Crank Engine, or Cranks Slow.

  • Page 112: Diagnosing Electronically Controlled Fuel System Problems

    Diagnosing Electronically Controlled Fuel System Problems A Mercury Diesel authorized repair facility has the proper service tools for diagnosing problems on electronically controlled fuel systems. The engine control module (ECM) on these engines has the ability to detect problems with the system when they occur, and store a trouble code in the ECM's memory.

  • Page 113: Incorrect Engine Temperature

    Lubricate. fasteners. Obstruction in the shift or throttle linkages. Remove the obstruction. Check all throttle linkages. If any are loose or missing, see a Mercury Loose or missing shift and throttle linkages. Diesel authorized repair facility immediately. 90-8M0113987 DECEMBER 2015...

  • Page 114: Steering Wheel Turns Hard Or Jerky

    Drive belt loose or in poor condition. Replace or adjust. Insufficient lubrication on the steering components. Lubricate. Check all parts and fasteners; if any are loose or missing, see a Mercury Loose or missing steering fasteners or parts. Diesel authorized repair facility immediately.

  • Page 115: Section 7 - Customer Assistance Information

    Section 7 - Customer Assistance Information Section 7 - Customer Assistance Information Table of Contents Owner Service Assistance..........108 Contact Information for Mercury Marine Customer Local Repair Service ..........108 Service ............... 109 Service Away From Home .......... 108 Customer Service Literature..........109 Stolen Power Package ..........

  • Page 116: Owner Service Assistance

    If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

  • Page 117: Contact Information For Mercury Marine Customer Service

    Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: •...

  • Page 118: Other Languages

    Section 7 - Customer Assistance Information Other Languages To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.
  • Page 119 Section 8 - Maintenance Log Section 8 - Maintenance Log Table of Contents Scheduled Maintenance Log..........112 Vessel Maintenance Notes..........113 90-8M0113987 DECEMBER 2015 Page 111...

  • Page 120: Scheduled Maintenance Log

    Section 8 - Maintenance Log Scheduled Maintenance Log 100 Hours Actual Hours Service Notes Dealer Name Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name...

  • Page 121: Vessel Maintenance Notes

    Section 8 - Maintenance Log Vessel Maintenance Notes Record all general maintenance performed on your power package here. Save all work orders and receipts. Engine Date Maintenance Completed Servicing Dealer Hours 90-8M0113987 DECEMBER 2015 Page 113...
  • Page 123 Parc Industriel de Petit-Rechain 41-71 Bessemer Drive P.O. Box 1939 B-4800 Verviers, Belgium Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA © Mercury Marine. All rights reserved. 90-8M0113987 NOVEMBER 2015 Printed in U.S.A.

This manual is also suitable for:

4.2 diesel

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